Stretchable garments and manufacturing method

ABSTRACT

A one-size-fits-all garment (10) is formed of multiple stretchable fabric portions (2) joined together by a PBT (polybutylene terephthalate) thread (38). The garment includes a waistband (6) that uses a paper fusing technique to fuse a fusing material from a paper backing sheet (18, 18A, 18B), onto the waistband which is also joined to the stretchable fabric portions using PBT thread. A method for forming the garment includes using a sheet of carrier paper with a fusing material such as a plurality of discrete dots of fusing material, to the waistband and sewing the multiple stretching stretchable fabric portions together and to the waistband using the PBT thread.

TECHNICAL FIELD

The disclosure relates to stretchable garments and methods for manufacturing the same. More particularly, the disclosure relates to a stretchable, one-size-fits-all garment and methods for making the same.

BACKGROUND

In today's very competitive textile industry, stretchable garments formed of elastic fabric materials are becoming very popular for workouts and for participation in sports and other athletic activities, and also to provide form-fitting garments for casual and even formal wear. It would be advantageous to be able to manufacture garments with an elasticity throughout the garment, that enables a particular garment to stretch to fit wearers of different body sizes. Stretchable garments may be formed by joining multiple stretchable fabric portions together. Manufacturing costs are saved when fewer sizes are required to be manufactured. Fewer sizes are needed when a single garment is manufactured to a particular garment size that can be stretched and worn by wearers of different sizes, e.g. a single garment can be worn by people of different sizes. Fewer sizes are also required when garments are manufactured to the same particular garment size at the manufacturing facility, but then can be modified and fixed at different sizes to accommodate wearers of different sizes.

The stretchability of a garment and therefore the number of different sizes that a particular size garment can accommodate, is determined by the elasticity of the stretchable fabric material itself, and the materials and techniques used to join the stretchable fabric portions together.

Elastic/stretchable fabrics are formed of the elastomeric yarns or threads that can only attain a certain maximum elongation. After reaching the maximum elongation, if the elastomeric threads are stretched further, they break or become otherwise deformed to the point where they cannot recover to their original dimension, effectively destroying the fabric material. The challenge is to form an entire garment that can stretch to a significant amount without tearing or deforming and which can still return to its pre-stretched state.

The disclosed invention addresses these concerns.

SUMMARY

The present invention provides a one-size-fits-all garment, i.e. a garment that can be worn by users having different body sizes, formed of multiple stretchable fabric portions joined together by a thread that can stretch with the garment, to the same extent, preferably a polybutylene terephthalate (PBT) thread. The garment may include a waistband, preferably of the same material of the rest of the garment, that has a further material fused to it using paper fusing technique. Preferably, the waistband is also joined to the stretchable fabric portions using PBT thread. A method for forming the garment includes fusing a fusing material preferably as a plurality of discrete pieces of fusing thermoplastic material from a paper carrier sheet, to the waistband and sewing the multiple stretchable fabric portions together and to the waistband using the PBT thread. The PBT thread has a superior elasticity that is equal or greater than the elasticity of the stretchable fabric portions and therefore the seams formed when the stretchable fabric portions are joined together, do not limit the stretchability of the overall garment. The fusing thermoplastic material is used to provide additional strength to portions of the highly elastic fabric (such as the waistband) without impairing the elongation characteristics of the fabric. PBT threads suitable for the present invention are commercially available, e.g. Eloflex (by Coats, UK) and as Aneflex (by American & Efird, US).

The PBT threads of the invention contain at least a filament of PBT to provide the required stretchability and elongation. A PBT sewing thread is disclosed in US 2006/0213176.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not necessarily to scale. On the contrary, the dimensions of the various features may be arbitrarily expanded or reduced for clarity. Like numerals denote like features throughout the specification and drawings.

FIG. 1 is a front, plan view of a garment according to an embodiment of the invention;

FIG. 2 is a side view of the garment shown in FIG. 1;

FIG. 3 is a perspective view of a waistband for a garment according to embodiments of the invention;

FIG. 4 is a perspective view of a paper-fused waistband according to an embodiment of the invention;

FIG. 5 is a cross-sectional view of embodiments of a waistband during a paper fusing stage, according to the invention;

FIG. 5A-5C are views of a waistband in possible embodiments of the invention;

FIG. 6 is a front, plan view of another garment according to an embodiment of the invention;

FIG. 7 shows chain stitching of a polybutylene terephthalate (PBT) thread according to an embodiment of the invention; and

FIG. 8 is a flow chart illustrating a method according to an embodiment of the invention.

DETAILED DESCRIPTION

According to some embodiments, the disclosure provides a stretchable garment comprising: stretchable fabric portions joined together by PBT (polybutylene terephthalate) thread; and an elastic waistband joined to one or more of the stretchable fabric portions by PBT thread.

In some aspects, the stretchable garment further comprises the stretchable waistband, or another portion of the garment, having a further material (a so called fusing material) applied thereto, preferably fused thereto. The material typically is a thermoplastic material that is applied to a side of the fabric by transfer from a carrier paper. A suitable fusing material is polyamide (PA). The said material is applied to a portion of the fabric to impart to it greater strength to improve its look; a waistband is typically such a portion of the garment. At the same time, the portion of fabric in the garment carrying the fusing material should remain elastic enough to stretch together with the parts of garment that are attached to the reinforced portion having the fusing material applied thereto.

In some aspects, the stretchable garment includes stretchable fabric portions formed of spandex or other elastomers, i.e. fabric portions including elastomeric yarns.

In some aspects, the stretchable fabric portions are formed of a fabric material characterized by having at least a 50%, preferably a 60% stretch in weft direction according to ASTM D3107. The fabric material preferably is a woven fabric.

In some aspects, the stretchable garment includes the stretchable fabric portions joined together by the PBT thread in a chain stitch configuration. In some aspects, the PBT thread is 100% PBT. The stretchable garment may further comprise hems formed of PBT thread.

The stretchable garment may include the further material for strengthening the fabric applied or fused to the waistband or to another part of the garment, the material comprising a plurality of discrete dots or portions of the material. Said material is preferably a thermoplastic material. The reason of applying fusing is also to keep the form of the waistband more “rigid” so it can wrap the body more firmly thus helping in holding the pants in place.

As above discussed, it is applied a type of fusing which includes the use of dots or portions of material (also called “sugars”) on a carrier paper. After applying this fusing material on the fabric, e.g. by heat pressing, the paper is removed and only the plurality of spaced dots, or spaced portions of fusing material, remains on the waistband. While the dots are giving the required rigidity to the waistband (or to another portion of the garment's fabric), as they are spaced from each other and there is no connection in between them, the elasticity of the waistband is maintained at a level sufficient to allow high stretch. Thanks to the help of this feature and manufacturing step, a size 24 garment according to the invention can be stretched to size 40 and used as such, while the current products in the market can only be stretched to provide a size 32.

According to some aspects, the stretchable garment includes the stretchable fabric portions comprising denim.

According to some aspects, the stretchable garment includes the further material applied at least to the waistband comprising a polyamide-based nylon material.

According to some aspects, the stretchable garment is tight fitting legwear.

According to some embodiments, the disclosure provides a stretchable garment comprising: stretchable denim fabric portions joined together by polybutylene terephthalate (PBT) thread in a chain stitch configuration; an elastic waistband joined to one or more of the stretchable denim fabric portions by PBT thread, hems formed of PBT thread, and the elastic waistband having a plurality of discrete dots of a polyamide-based nylon material, fused thereto.

According to some embodiments, the disclosure provides a method for manufacturing a one-size-fits-all garment, the method comprising: sewing stretchable fabric portions together using polybutylene terephthalate (PBT) thread; applying or fusing a material onto a part of the garment, preferably a waistband; and joining the waistband to one or more of the stretchable fabric portions by sewing with PBT thread.

In some aspects, the sewing comprises sewing using a chain stitch configuration.

In some aspects, the stretchable fabric portions are formed of a fabric including elastane and the fusing material comprises a polyamide-based nylon material.

In some aspects, the stretchable fabric portions are formed of a material characterized by having at least a 50%, preferably a 60% stretch rate in weft direction (ASTM D3107). The material is preferably a woven fabric. In preferred embodiments, the fabric is weft stretch.

In embodiments the warp yarns may have an English cotton number between approximately Nm 16 and Nm 150, preferably 30 to 140 Nm, inclusive. Elastic yarns that are used as weft yarns in weft stretch fabrics, or as warp and weft in bi-stretch fabrics, may have a denier between approximately 30 and 240 dtex preferably 40 to 150 or 200, inclusive.

In some aspects, the method comprises hemming the stretchable fabric portions by sewing with PBT thread.

In some aspects, the PBT thread is 100% PBT and the waistband and the stretchable fabric portions of the garment are formed of the same material.

In some aspects, the method includes the fusing, which step is comprising fusing a plurality of discrete dots to the waistband, or another part of the garment.

In some aspects, the method includes the stretchable fabric portions comprising denim.

In some aspects, the method includes the garment comprising tights.

The present invention provides multi-size, or one-size-fits-all, garments, alternatively referred to as one-size-for-all garments. The garments are formed of stretchable elastic fabrics that have various elongation rates, some as high as 65-75%. Alternatively stated, the fabric material used to form the stretchable fabrics used to form the garments, can stretch to 65-75% of its original length without tearing or other deformation in various embodiments.

After stretching, the stretchable fabric material can recover or substantially recover to its original dimensions. A wearer having a size greater than the garment size can wear the garment and afterwards the garment returns substantially to its original garment size without defect. The disclosed garment is made of multiple stretchable fabric portions stitched or otherwise joined together using polybutylene terephthalate (PBT) thread.

In various embodiments, the stretchable fabric material may include elastic yarns, preferably at least weft yarns, comprising elastane, lycra, spandex, polybutylene terephthalate (PBT) or other synthetic fabric materials that stretch such as described below. The stretchable fabric materials may be a 2-way stretchable fabric, i.e. it stretches in one direction, or it may be a 4-ways stretchable fabric such as obtainable from spandex, which stretches in both directions, crosswise and lengthwise. Spandex is an elastomeric stretchable material formed of a polyether-polyurea copolymer. The stretchable fabric is a fabric made with at least some stretchable yarns that extend in the weft direction, or in the warp direction or in both the weft and the warp directions. In various embodiments, the elastomeric yarns may have a denier in the range of approximately 40 to 140 denier, but other elastomeric yarns may be used in other embodiments and stretchable fabric materials formed from other types of elastomeric yarns may be used in other embodiments.

The fabric may be any suitable stretchable fabric with constant elasticity through the fabric. In some embodiments, the elasticity in the warp direction may vary from the elasticity in the weft direction and in other embodiments, the elasticity is the same in both the warp and weft directions. In some embodiments, the stretchable fabric is an untreated fabric. In some embodiments, the stretchable fabric is an uncoated fabric and in some embodiments, the fabric is an untreated, uncoated fabric, but the fabric may be treated and/or coated in other embodiments.

The fabric is advantageously formed of a stretchable fabric that is a woven fabric according to various aspects of the disclosure. The stretchable fabric may be a woven fabric material with inelastic and elastic fibers. The fabric may be stretchable denim according to various advantageous embodiments but in other embodiments, the fabric may be one of any of various other suitable stretchable fabrics. Stretchable fabrics suitable for the invention are known per se in the art. Examples of suitable fabrics are known e.g. from EP 15177938.6, EP16714831.1 and EP 2832907 as far as said fabrics meet the requirement of having an elongation in the weft direction of at least 50%, preferably at least 60% as measured by ASTM D3107.

Some examples of elastomeric fibers that provide high degrees of elasticity are elastane and spandex, T400, PTT, PBT and elastomultiesters (or elastoesters) and the bicomponent polyesters Poly(Trimethylene Terephthalate)/Polyethylene Terephthalate (PTT/PET) and other similar materials. Some examples of fibers suitable for the sheath of the elastic core include natural and synthetic fibres such as cotton, wool, polyester, rayon, nylon, polyesters. The identified elastomeric fibers are provided by way of example only and in various embodiments, any of suitable various elastomeric fibers or combinations of different elastomeric fibers may be used for the stretchable fabric.

The fabric may be formed of various fibers that may include fibers formed into various yarns that include multiple fibers. In some embodiments, both inelastic and elastic fibers extend in both the warp and weft directions of fabric. In various embodiments, elastomeric material may be cast into mono-filaments and/or located into staple fibers and may be utilized as-is or together with other fibers in a yarn.

In some embodiments, the stretchable fabric is formed of elastic yarns that include an elastic core of one or more elastic fibers or filaments with an inelastic sheath covering the core. The inelastic sheath may be formed of cotton or other natural materials and in some embodiments, the inelastic sheath may be formed of synthetic materials.

Various methods for forming a yarn by combining a stretchable core including one or multiple fibers that have elastic properties, with an insulating sheath covering, are provided in US patent application Publ. No. 2013/0260129, the contents of which are hereby incorporated by reference as if set forth in their entirety. In some elastic core yarn embodiments, the core includes a bundle of one or multiple fibers, some or all of which are elastic. The fibers that make up the core may be connected together by twisting, intermingling or co-extrusion (or co-feeding). In some embodiments in which the fibers are intertwined, they can be intertwined to various degrees. The elastomeric core is characterized by excellent recovery and resiliency properties provided by one or more of the core fibers.

In various embodiments, the fabric yarns include multiple elastic fibers that may be formed of the same or different material and with the same or different degrees of elasticity. In some embodiments, one of the fibers may be stretchable to a length of 400% of its original length and one of the other fibers may be less elastic but stretchable to at least about 20% of its original length. In other embodiments, the fibers used represent other combinations of the fibers that have different degrees of elasticity. In some embodiments, the stretchable fabric is formed of thermoplastic elastic fibers. In some embodiments, thermoplastic elastomers and thermoplastic polyurethanes (TPU) having a well-combined structure of soft and hard building segments that provides exceptional elasticity, are used. Various elastic polyurethane materials, collectively referred to as elastanes, may be used.

Core-spun and ring spun technologies are known and widely used processes in the textile industry, and involve combining two or more fibers with different features, to form one yarn member. These and various other methods for spinning fibers to produce yarns may be used to form the stretchable fabric

In some embodiments, stretchable woven pieces with elongation rates of at least 50%, preferably at least 60%, e.g. 60%-200% in the weft direction and 0%-200%, preferably 4-200% in the warp direction, as measured by ASTM D310, are used. Other suitable stretchable fabric materials may be used in other embodiments.

The garment includes multiple stretchable fabric portions joined together by polybutylene terephthalate (PBT) thread. The PBT thread has an elasticity characterized by an ability to be stretched of up to 85 to 90%. In some embodiments, the thread is 100% PBT and in other embodiments the thread is formed primarily of PBT. In other embodiments, other suitable sewing threads with elastic properties similar to that of PBT may be used, for example a combination of PBT with a suitable material such as nylon that produces an elasticity (stretchability) greater than 50%. In general, the sewing threads may have an elasticity that is comparable to or greater than the elasticity of the fabric.

Various methods and various configurations may be used to sew together the stretchable fabric portions using PBT, to form various seams in the garment. The PBT thread may also be used to join the stretchable elastic fabric portions of the garment to other portions of the garment such as the waistband, belt loop, risers, various other panels, hems and other garment features. Various types of seams and various types of stitching configurations may be used to join the stretchable fabric portions together or to other portions of the garment. In various embodiments, the various hems of the garment are also formed using PBT thread or a thread of an equivalent material as above mentioned.

In various embodiments, the garment may be a pair of trousers, a pair of shorts, bathing attire, undergarments, running tights, fitness tights, socks, shirts and other upper and lower body garments. In various embodiments in which the garment includes a stretchable waistband, the stretchable waistband may be formed of the same materials as the body fabric but other suitable elastic materials may be used in other embodiments. The stretchable waistband is joined to one or more of the stretchable fabric portions by PBT thread.

According to another aspect, the stretchable waistband or another portion of fabric that might need to be strengthened, undergoes a process to apply a further material to the waistband or fabric portion. A particular process is used which does not adversely affect the elastic properties of the waistband. A suitable technique is applying a plastic material by fusing. Fusing is the thorough blending of material as if by melting together or may be considered to be a process that combines layers of material by applying heat and pressure with or without the use of an adhesive.

The fused material may advantageously be fused to the inside of the waistband to provide a more compact form but the fused material may alternatively or additionally be to the outside of the waistband in other embodiments. When the waistband is made of two portions sewn together or by a folded portion, the material may be applied internally to the waistband. The applied material provides a degree of rigidity to the waistband (or to another part of the garment) so that it does not appear too flaccid and retains its original shape and does not fit too loosely. In some embodiments, a preferably discontinuous piece of material is fused to either or both sides of the waistband. In other embodiments, a number of individual, separate portions of fusing material may be applied or fused to either or both sides of the waistband. The separate portions of thermoplastic material are preferably in the form of a plurality of dots or small areas. The said separate portions are spaced of a length sufficient to substantially maintain the original stretch characteristics (elongation ASTM D3107) of the material of the waistband or other part of the garment to which the material has been added. Various types of paper including laminated paper may be used as a backing or carrier sheet to which the fusing material is initially coupled. Various types of fusing machinery are available and can be used with various temperature settings, pressure settings, fusing times and other parameters so as not to degrade the elasticity of the waistband. As mentioned, the additional material may be applied to other parts of the garment, if so required to improve rigidity, i.e. to strengthen the otherwise loose fabric portion.

Because of the foregoing aspects, a garment can be manufactured to a single size but can be stretchable to various other sizes to accommodate users of various sizes without having to alter the garment. This is true for various garments and is particularly advantageous for tight fitting legwear. In one embodiment for women's legwear, i.e. more generally referred to as women's bottom products, the garment is manufactured to a standard garment size 24 but can be stretched to comfortably accommodate wearers of sizes as great as 40. Prior art elastic garments can only stretch from size 24 to size 31-32.

Now turning to FIG. 1, garment 10 is a pair of tights such as used in running, cycling or various other workout or other athletic activities, in the illustrated embodiment of FIG. 1. Garment 10 may alternatively be fashion tights. Garment 10 is formed of multiple portions 2 of stretchable fabric material. The stretchable fabric portions 2 may also be referred to as stretchable fabric panels 2. Stretchable fabric material is used to form various types of garments and can have various types of elasticities.

Garments with high degrees of elasticity can be obtained using various elastomeric materials such as polyurethanic fibers that can stretch to considerable lengths without breaking. Examples of elastomeric fibers are lycra, elastane and spandex and similar materials as described above. Stretchable fabric portions 2 are formed of materials such as, but not limited to the aforementioned stretchable fabric materials such as elastane, spandex, lycra and PBT. In other embodiments, other suitable stretchable fabric materials may be used as stretchable fabric portions 2. In some embodiments, stretchable fabric portions 2 are formed of stretchable denim.

In the illustrated embodiment of FIG. 1, the two stretchable fabric portions 2 are joined to one another at seam 4 using PBT thread. In some embodiments, the PBT thread is 100% PBT and in other embodiments, other suitable materials with elastic properties similar to that of PBT, may be used. The PBT thread may be a single fiber or multiple fibers that combine to form the PBT thread. In some embodiments, the PBT thread is treated or coated with suitable lubricants to improve sewability.

Various examples of the PBT thread may include dimensions and qualities as indicated in the following table. As can be seen, in some embodiments, the PBT thread has a maximum elongation of up to 90%.

TABLE 1 Tex elongation % Min-Max 27 50-70 40 55-85 70 65-90 105 60-90 135 60-90

“Tex” is a unit of linear mass density for thread or fiber, defined as a milligram per meter. The “Elongation %” may be obtained according to Standard Test Methods for Sewing Threads ASTM D204-02 in which the sewing thread breaking test method provides the elongation rate at the time of break. The preceding Table 1 is provided by way of example only and in other embodiments, PBT thread with other physical characteristics, may be used.

Various seam types may be used such as doubly or triply stitched seams or lock stitch seams, chain stitched seams, serging stitched seams, cover stitch seams, flat lock stitched seams, zig zag stitched seams, blind stitched seams, safety stitched seams and the like. Other seam types may be used in other embodiments. The seams may be hand-sewn or machine sewn. In various embodiments, seam 4 may be a plain seam, a chain stitch seam, a French seam, a flat or abutted seam, or a lapped seam but still other seam types may also be used.

Hems 12 are also formed at the ends of the stretchable fabric portions 2 that make up garment 10. Hems of various configurations may be used and hems 12 are also formed of PBT thread.

Waistband 6 is formed of an elastic material and is joined to two of the stretchable fabric portions 2 at waistband seam 8. Various types of stitching techniques and configurations may be used to form waistband seams 8. At waistband seam 8, a PBT thread is used to join waistband 6 to one or more stretchable material fabric portions 2. Various stitching types may be used. In the illustrated embodiment of FIGS. 1 and 2, waistband 6 is joined to four stretchable fabric portions 2.

FIG. 2 shows a side view of garment 10 shown in FIG. 1. Seam 4 extends along the side of garment 10 and also joins together two stretchable fabric portions 2. Seam 4, like all other seams, is formed by PBT thread. Various stitching configurations may be used to form seam 4, hem 12 and waistband seam 8.

An advantage of the garment formed using stretchable fabric portions to be joined together by PBT thread is that the stretchability of the garment is not limited by the material used to form the seams and to join together stretchable fabric portions 2. In this manner, the stretchability of the garment is maximized and a garment manufactured to a particular size, can comfortably stretch to a size much larger.

In one embodiment, conventional size 24, can comfortably stretch to a size 40 due to a fabric elongation of 65 to 75% not limited by the stitching thread used to join the stretchable fabric portions. Such an exemplary garment, manufactured to a women's bottom products garment size 24, can be worn comfortably by a wearer of size 40, without the fibers of the fabric or seams being torn or otherwise degraded. In this manner, after the garment is worn by a wearer of size 40, the garment may return to its original, relaxed garment size 24 and may be worn by a wearer having size 24. It should be understood that the aforementioned examples using the two exemplary sizes of size 24 and 40, is presented by way of example only and in other embodiments the garment can be manufactured to various relaxed garment sizes and comfortably stretched to various maximum wearer sizes, and this applies to various types of garments produced according to the disclosure.

FIG. 3 shows a perspective view of waistband 6. Various woven fabrics or nonwoven materials formed of various different types of synthetic polymers may be used for waistband 6. Waistband 6 includes inside portion 14 and outside portion 16. Waistband 6 is chosen in conjunction with the fabric used to make stretchable fabric portions 2, so that waistband 6 can stretch to at least the same degree as stretchable fabric portions 2. In various embodiments, waistband 6 is formed of the same fabric or material as the fabric used to make stretchable fabric portions 2. In some embodiments, waistband 6 may be formed of any of the various materials referred to above in the description of fabric portions 2, but still other materials may be used for the waistband in other embodiments.

Waistband 6 undergoes paper fusing according to advantageous aspects of the disclosure. In some embodiments, material is fused to inside portion 14 and in some embodiments, material is fused to outside portion 16 and in some embodiments, the material is fused to both inside portion 14 and outside portion 16. Paper fusing involves the use of paper as a carrier layer upon which a continuous adhesive material or a plurality of discrete portions of adhesive material, is disposed.

FIG. 4 is a perspective view of a paper-fused waistband during a fusing stage, according to an embodiment of the invention. Fused material 20 is on paper carrier sheet 18 and is fused to outside portion 16 of waistband 6. Fused material 20 is a material that may extend almost to upper 22 and lower 24 edges of waistband 6. In other embodiments, other arrangements and other relative dimensions of waistband 6 and fused material 20, are used. According to the fused waistband embodiment, fused material 20 is fused to waistband 6 to form a preferably discontinuous laminate along waistband 6. Fused material 20 is originally affixed to paper carrier sheet 18 which is later removed after the process stage illustrated in FIG. 4. Fused material 20 may be an adhesive polyamide based nylon material, but other materials such as elastic or inelastic fabric materials, or other suitable non-fabric materials may be fused to waistband 6, in other embodiments.

FIG. 5 is a cross-sectional view of waistband 6 at a stage during the fusing operation before all the paper carrier sheets are removed. FIG. 5 shows waistband 6, inside portion 14 with material fused to it and outside portion 16 with material also fused to it. Various types of paper can be used as a carrier for the material to be fused, and the paper is removed subsequent to the fusing operation but is shown in FIGS. 4 and 5. Various fusing machines for garments are commercially available and function by causing two materials such as a fabric and another material, pressed together between rollers while being heated. In some embodiments, a continuous sheet of material is set on backing paper and is passed through the fusing machine and fused to the waistband. In some embodiments, the fusing material includes an adhesive on one or both faces thereof. In some embodiments, a sheet of adhesive dots is affixed to a paper carrier sheet and fused to the waistband

FIG. 5 shows fused material 20A fused to inside portion 14 of waistband 6 and disposed on paper carrier sheet 18A. In contrast, on outside portion 16 of waistband 6, the fused material is in the form of multiple discrete fused dots 20D. Fused dots 20D are shown affixed to waistband 6 after removal of paper carrier sheet 18B. In some embodiments, each of inside portion 14 and outside portion 16 has material fused to it and in other embodiments, only one of inside portion 14 and outside portion 16 undergoes paper fusing that fuses a material to it. Either or both of inside portion 14 and outside portion 16 may have continuous fused material such as 20A or either or both of inside portion 14 and outside portion 16 may have discrete portions of fused material such as discrete fused dots 20D. The paper carrier sheet may be a continuous paper sheet that may include adhesives on one of its surfaces.

In possible embodiments, as the one shown in FIGS. 5A and 5B, fused material 20 (e.g. in the form of fused dots 20D in the figures) is firstly applied to a carrier sheet 18, and subsequently applied to one side of the waistband 6. Subsequently, the carrier sheet is removed and the fused material 20 remains on the waistband 6.

In a possible embodiment, as shown in FIG. 5B, the waistband is folded along the size where the fused material 20 was applied, so that to join the bent portions of the relevant side of the waistband 6 via the fused material 20D.

In possible alternatives, the waistband is provided with a plurality of separate pieces. The fused material is applied to at least one of the pieces, and subsequently the different pieces are joined one to the other via the fused material 6.

The carrier is removed so that, in preferred embodiments, two portions of the waistband (i.e. portions of a folded waistband or previously separate pieces) are joined directly one to the other via the fused material, i.e. without any further layer interposed therein.

The fused material may have lower elasticity (i.e. stretchability) with respect to the waistband 6. As a result, the elasticity of the waistband 6 may decrease at the point joined via the fused material 20. Preferably, as discussed, the fused material is not arranged continuously along the waistband, to maintain a sufficient degree of elasticity. In other words, the elasticity of the entire waistband is not jeopardized by the presence of the fused material 20. Furthermore, it is possible to decide the arrangement of the fused materials 20 to decide how much it will affect the elasticity of the final waistband. As an example, in FIG. 5A, it is shown that the fused material 20 is applied substantially along the entire area of the waistband (in more detail, on the entire area of the carrier sheet and, consequently, on the waistband 6, once the carrier sheet is applied and subsequently removed from the waistband 6).

However, the fused material 20 may be applied in one or more different areas of the waistband 6, before it is folded. As a result, before folding or coupling with another piece of the waistband, there are at least some portions of the waistband that are free from fused material 20. Some exemplary embodiments where the fused material 20 is applied only onto portions of the waistband 6 (or portions of a piece of a waistband), while other portions are free from fused material are shown in FIG. 5C.

As evident, the above are only exemplary embodiments, and other solutions (e.g. more complex patterns, fused material 20 applied only at the perimeter of the waistband 6, etc.) are possible. The waistband 6 is typically bi-dimensional, substantially rectangular, having a longer side and a smaller side. In some embodiments, where the fused material 20 is applied via discrete elements (e.g. dots 20D) onto the waistband (or piece of a waistband), it is possible to draw on the waistband, or piece of the waistband, a first square that does not contain any fused material 20, and a second square containing fused material 20, the first and second square having side having side at least 10%, preferably at least 25% of the smaller side of the waistband 6. In other words, in the embodiments where the fused material 20 is applied as dots 20D, a free portion has a dimension greater than the distance between the dots 20D, i.e. the space between the dots does not form a free portion within the present meaning. A free portion is in fact a greater area of the waistband 6 (or piece of a waistband) onto which the fused material is not applied.

It should be noted that, for easiness of discussion, discrete elements have been discussed as “dots”. More in general, in the embodiment in which multiple discrete portions are fused to the waistband, the multiple discrete portions or elements may be in the form of dots, squares, diamond shapes and various other geometric shapes. The discrete geometric shapes may be in various arrangements along inside portion 14 or outside portion 16 of waistband 6. In the fusing operation, the discrete geometric shapes may be disposed on a layer of release material such as a paper carrier sheet, then the discrete geometric shapes are fused to the waistband and the layer of release material is removed. The paper fusing gives the waistband a smooth look and maintains the original form of the waistband. The layer of release material may be paper but other suitable materials may be used in other embodiments.

In general, the use of a fused material applied via discrete elements (e.g. dots) provides a greater strength and consistency to the fabric at the waistband, while maintaining the fabric.

The starting fabric for the waistband, and in general the fabric of the garment of the present invention, has a weight ranging from 80 g/sqm to 500 g/sqm, measured according to ASTM D3776, preferably 100 g/sqm to 400 g/sqm

The fusing procedure does not adversely affect the elastic properties of the waistband because of the fusing conditions used. According to the present invention, the special fusing process joins the fusing material, formed on a paper carrier sheet, to the waistband material and fuses them together using a fusing process. In some embodiments, the fusing process takes place at about 115-135° C. for a time ranging from about 10 s to 20 s and using a pressure in the range of about 2-5 N/cm². Other temperatures, times and pressures may be used in other embodiments and the fusing conditions, particularly the pressures, are determined at least in part by the type of fusing press used. When discrete portions are fused such as dots, squares, etc., formed of polyamide-based material, such as nylon, or other suitable materials are fused, any backing material such as paper can be removed immediately after fusing, i.e. while the materials are still hot.

FIG. 6 shows another embodiment in the form of a pair of trousers, according to an embodiment of the present the invention. Trousers 30 are formed of any of the various stretchable fabric materials described above and in some advantageous embodiments, trousers 30 are jeans formed of stretchable denim. Trousers 30 include various seams 4 as described above and seams 4 are used to join together the various stretchable fabric portions 2 of trousers 30. Belt loops 32, pockets 34 and various other stretchable fabric portions are joined to one another by seams 4.

Hems 12 are also formed at edges of stretchable fabric portions 2 such as shown in FIG. 6. Both seams 4 and hems 12 are formed of PBT thread and various types of stitching techniques such as loops or chain stitching or various other suitable types of stitch configurations, can be used. Waistband 6 is sewn to stretchable fabric portions 2 using PBT thread which forms waistband seam 8. Various stitching configurations may be used to form seam 4, hem 12 and waistband seam 8. According to the trousers 30 embodiment, waistband 6 may be formed of an elastic material that is different than stretchable fabric portions 2, or waistband 6 may be formed of the same material as stretchable fabric portions 2.

FIG. 7 shows PBT thread 38 as described above. PBT thread 38 is in a chain stitch 40 orientation which represents just one of a variety of embodiments of stitching orientations that may be used to form seams 4 and 8, or hem 12 as previously discussed.

The disclosure also provides a method for manufacturing the stretchable garments. In some embodiments, the method for manufacturing a one-size-fits-all garment includes sewing elastic fabric portions together using PBT (polybutylene terephthalate) thread, fusing a further material from a paper backing sheet to a waistband and joining the waistband to one or more of the elastic fabric portions by sewing with PBT thread. The sewing may be carried out by a machine or the seams and hems may be hand-sewn.

FIG. 8 shows a flow chart of a method according to embodiments of the invention. At step 100, provide portions of stretchable fabric, the stretchable fabric portions may be formed of the various fabrics and yarns recited above and may be produced using various fabric production methods. The stretchable fabric is tailored and cut into the various panels or portions to be joined together to form the garment of the stretchable fabric. Various garments with various relaxed base sizes may be produced and the various stretchable fabric portions sized accordingly. The garment is formed by joining the various stretchable fabric portions to one another and also to a waistband using various suitable techniques for joining pieces of fabric together by stitching using a thread. The thread is formed of PBT and is also used to form hems.

At step 102, join stretchable fabric portions, the stretchable fabric portions are joined to one another by sewing with PBT thread.

At step 104, waistband paper fusing, the method provides for fusing an adhesive polyamide-based nylon, or other suitable material, from a paper carrier layer, to a waistband using conditions that do not adversely affect the elasticity of the waistband. A continuous sheet of elastic material may be fused to the waistband or preferably discrete portions of material may be fused to the waistband. Different portions or pieces of the waistband may be joined via the fused material. The waistband is then joined to the stretchable fabric portions using PBT thread at step 106.

An advantageous aspect of the invention is that the garments described above, can be manufactured to one unstretched, i.e. relaxed “base” size, but can be comfortably worn by users having various different sizes because the garment can stretch to accommodate wearers of various sizes and can do so without any limitation due to the inability of the seams to stretch to the same degree as the stretchable fabric. According to the invention, the seams formed of PBT thread can stretch to the same or greater extent than the waistband and stretchable fabric, thus avoiding any problem in which the stretchability of the garment is limited by the stretchability of the seams. In some embodiments, the PBT thread can attain an elongation of as high as 85 or 90%. Also according to the invention, after the garment manufactured to a particular relaxed garment size is worn by a wearer of a greater size, the garment recovers substantially to its original relaxed garment size and can be worn by a wearer of the relaxed garment size.

In some embodiments, according to European sizing, a stretchable garment can be manufactured to a resting, un-stretched “base” size of women's legwear size 24. This stretchable garment having an unstretched “base” size of 24, can be comfortably worn by wearers whose size measurements range from size 24 to size 40. This enables the manufacturing facility to produce a stretchable garment of a single base size, e.g. European woman's legwear size 24 in the present example, that can be worn by various sized wearers and can return to its original relaxed base size of 24 after being worn. In this embodiment, a manufacturer can essentially just produce one size garment that fits all wearers.

In other embodiments, a manufacturer may manufacture garments having a different base, i.e. unstretched size and in still other embodiments, a manufacturer may manufacture two base-sized stretchable garments for shipment.

The preceding merely illustrates the principles of embodiments of the disclosure. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended expressly to be only for pedagogical purposes and to aid the reader in understanding the principles of the invention and the concepts contributed by the inventors to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.

This description of the exemplary embodiments is intended to be read in connection with the figures of the accompanying drawing, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. 

1. A stretchable garment comprising: stretchable fabric portions joined together by PBT (polybutylene terephthalate) thread; and an elastic waistband joined to one or more of said stretchable fabric portions by PBT thread.
 2. The stretchable garment as in claim 1, said stretchable waistband having an additional material applied thereto.
 3. The stretchable garment as in claim 2, wherein different stretchable fabric portions of the waistband are joined directly one another via said additional material, without a further layer interposed therein.
 4. The stretchable garment as in claim 2, wherein said stretchable fabric portions include elastic and/or elastomeric yarns, containing spandex fiber.
 5. The stretchable garment as in claim 1, wherein said stretchable fabric portions are formed of a material characterized by having at least a 50% stretch in weft direction.
 6. The stretchable garment as in claim 1, wherein said stretchable fabric portions are joined together by said PBT thread in a chain stitch configuration.
 7. The stretchable garment as in claim 1, wherein said PBT thread is 100% PBT.
 8. The stretchable garment as in claim 2, wherein said additional material applied to said waistband comprises a plurality of discrete elements spaced from each other.
 9. The stretchable garment as in claim 1, wherein said stretchable fabric portions comprise denim.
 10. The stretchable garment as in claim 2, wherein said additional further material comprises a polyamide-based nylon material.
 11. The stretchable garment as in claim 1, wherein said garment comprises tight fitting legwear.
 12. A stretchable garment according to claim 1, comprising: stretchable denim fabric portions joined together by polybutylene terephthalate (PBT) thread in a chain stitch configuration; an elastic waistband joined to one or more of said stretchable denim fabric portions by PBT thread, hems formed of PBT thread, and said elastic waistband having a plurality of discrete elements of a polyamide-based nylon material fused thereto.
 13. A method for manufacturing a one-size-fits-all garment, said method comprising: sewing stretchable fabric portions together using polybutylene terephthalate (PBT) thread; applying a material, onto at least a waistband portion of the garment; and joining said waistband or other portion of the garment to one or more of said stretchable fabric portions by sewing with PBT thread.
 14. The method as in claim 13, wherein said stretchable fabric portions are formed of a fabric including elastic and or elastomeric yarn, and said fusing material comprises a polyamide-based material.
 15. The method as in claim 13, wherein said stretchable fabric portions are formed of a material characterized by having at least a 60% stretch in weft direction.
 16. The method as in claim 13, further comprising hemming said stretchable fabric portions by sewing with PBT thread.
 17. The method as in claim 13, wherein said PBT thread is 100% PBT and said waistband and said stretchable fabric portions are formed of the same material.
 18. The method as in claim 13, wherein said material is applied as a plurality of discrete spaced elements to said waistband.
 19. The method as in claim 13, wherein the stretchable fabric portions comprise denim.
 20. The method as in claim 13, wherein different portions of said waistband are joined via said fusing material, so that said different portions are directly joined by said material, without a further layer interposed therein. 